Process for making an adhesive dressing

Abstract: A process for making an adhesive dressing comprises passing a backing strip (16) continuously through an adhesive application zone (20); applying an adhesive (22) to one side of the backing strip as it passes continuously through this zone, to form an adhesive coated strip; and passing the adhesive coated strip from the adhesive application zone continuously through an adhesive conditioning zone (40,82), to condition the adhesive. Before or after the adhesive conditioning zone, the strip is passed continuously through a pad application zone (30,72) where pads (32) are applied to the adhesive coated side of the backing strip in such fashion that portions of the adhesive are not covered by the pad(s), thereby to form a padded strip. The padded strip is fed continuously and directly to a release paper application zone (50), where release paper (52,54) is applied over at least the adhesive, to form a continuous adhesive dressing.

Description: This invention relates to a process for making an adhesive dressing. CH-A-676197 discloses a process for making an adhesive bandage, in which adhesive is continuously applied to a backing strip and a release paper is then applied to cover the adhesive. In a subsequent operation, spots of adhesive are applied to a different region of the backing strip, and absorbent pads are then adhered to such spots of adhesive. US-A-2862846 discloses the manufacture of adhesive bandages from a laminate comprising a carrier paper, a plastic film, an adhesive layer on the plastic film, and a silicone coated release paper. According to the invention, there is provided a process for making an adhesive dressing, which comprises passing a backing strip continuously through an adhesive application zone; applying an adhesive to one side of the backing strip as it passes continuously through this zone, to form an adhesive coated strip; passing the adhesive coated strip from the adhesive application zone continuously through an adhesive conditioning zone, to condition the adhesive; before or after the adhesive conditioning zone, passing the adhesive coated strip continuously through a pad application zone where at least one pad is applied to the adhesive coated side of the backing strip in such fashion that portions of the adhesive are not covered by the pad, thereby to form a padded strip; and feeding the padded strip continuously and directly to a release paper application zone, where release paper is applied over at least the adhesive, to form a continuous adhesive dressing. The process of the invention is thus characterized thereby that it is continuous, ie the strip passes continuously and directly from one zone to the next, without intermediate taking up thereof into a roll. The adhesive may be a pressure sensitive adhesive. In one embodiment of the invention, the adhesive may be a curable adhesive such as a solvent or emulsion based adhesive. Curing of the adhesive may then take place in the adhesive conditioning zone. The pad may then be of curable foam material, as hereinbefore described, with the adhesive coated strip passing through the pad application zone before passing through the conditioning or curing zone, so that curing of the foam material is also effected in the conditioning or curing zone. In one version of this embodiment, the foam material may be applied continuously to the backing strip, eg so that a single pad extending along the strip is thereby provided. However, in another version, the foam material may be applied intermittently to the backing strip, eg so that a plurality of pads spaced longitudinally and/or laterally on the strip are thereby provided. Instead, the pad(s) may be of fabric. In one version of the invention, the fabric may be applied as a continuous strip to the adhesive coated strip. However, in another version of the invention, individual fabric pads may be applied intermittently to the adhesive coated strip. The fabric, when used as the pad material, is preferably, but not necessarily always, absorbent. The pad(s) can instead be of any other suitable material such as fibrous material or a gel. The adhesive coated strip may pass through the curing zone before application of the pad(s) thereto. In another embodiment of the invention, the adhesive may be a hot-melt adhesive applied to the backing strip at elevated temperature. Cooling of the adhesive may then be effected in the conditioning zone. The pad(s) may then, irrespective of whether they are in the form of a curable foam material, or a non-curable fabric, as hereinbefore described, preferably be applied to the adhesive coated strip after the adhesive has been cooled. Howver, when the pad(s) is/are of curable foam material, the process may include passing the padded strip through a curing stage prior to entering the release paper application zone. The process may include passing the continuous adhesive dressing from the release paper application zone to a cutting zone, and cutting it into individual dressings of a desired shape and size in the cutting zone. The cutting may be effected by means of a die cutting arrangement, eg by cutting a plurality of dressings side-by-side from the strip. The backing strip or layer may be cellulose based, may be in the form of a polymeric film, may be in the form of either a knitted or a non-woven fabric, may be of stretch or non-stretch form, or may be combinations thereof, as desired. When a foam material is used for the pad(s), it is preferably a SBR styrene butadiene rubber or a polyurethane foam. However, any other foam which can be coated as a relatively thin layer can be used. The foam may contain absorbency enhancing materials, such as acrylic superabsorbent powder. It may also contain a medication such as silver sulphur diazine and/or a facing layer such as a plastic net or a non-woven fabric. The pad can thus be continuous, ie extending along the strip with the adhesive coated zone(s) located alongside it. Instead, individual pads, spaced from one another along and across the strip, can be provided. The invention will now be described by way of example with reference to the accompanying diagrammatic drawings. In the drawings, FIGURE 1 shows a simplified flow diagram of a process for making an adhesive dressing, according to one embodiment of the invention; FIGURE 2 shows a side view of an adhesive dressing strip formed in the process of Figure 1; FIGURE 3 shows a side view of another adhesive dressing strip which can be formed in the process of Figure 1; FIGURE 4 shows a plan view of a cutting die for effecting the cutting operation in Figure 1; FIGURE 5 shows a plan view of an adhesive dressing formed by the process of Figure 1; and FIGURES 6, 7 and 8 shows simplified diagrams similar to Figure 1, of processes for making an adhesive dressing according to other embodiments of the invention. Referring to Figures 1 to 5, reference numeral 10 generally indicates a process for making an adhesive dressing, according to a first embodiment of the invention. The process 10 includes a backing strip feed zone 12 which contains a roll 14 of backing strip 16. The backing strip 16 can be cellulose based, can be in the form of a polymeric strip, can be knitted or non-woven, can be stretch or non-stretch, or can be combinations thereof. In the zone 12 is also provided feed means (not shown) for continuously feeding the backing strip 16 from the roll 14 to an adhesive application zone, generally indicated by reference numeral 20. In the zone 20 a curable adhesive, such as a solvent or emulsion based adhesive, is applied as a layer 22 to one side of the backing strip 16, as the backing strip 16 passes continuously through the zone 20. From the zone 20 the adhesive coated backing layer passes to a foam coating zone 30 where a foam material, such as polyurethane foam containing absorbency enhancing material such as acrylic superabsorbent powder is applied as a pad 32 to the adhesive coated side of the backing strip or layer 16. The pad 32 can be applied intermittently, or continuously, along the strip 16, depending on the eventual dressing required. From the zone 30 the strip passes to a curing/drying zone 40 where both the adhesive and the foam are cured/dried at elevated temperature. The strip 16 then passes to a release paper application or laminating zone 50, where overlapping release paper layers 52, 54 are applied over the pad 32 and the adhesive layer or coating 22, while the strip 16 passes continuously therethrough. Finally, the continuous adhesive dressing strip thus formed passes to a cutting zone 60 where it is cut, by means of a rotating cylindrical die 62, having raised cutting edges 64 defining desired dressing shapes and sizes on its outer surface, for cutting the strip into individual dressings of said desired shape and size. Thus, by means of the process 10, dressing strips 70, as indicated in Figure 2, can be formed. The dressing strips 70 thus comprise the backing strip 16, the adhesive layer 22 and the foam pad 32. Instead, a number of dressings can be formed side-by-side across the width of the strip 16, as indicated in Figure 3. After the adhesive dressing strip has been cut in the cutting zone, final dressings 80 as indicated in Figure 5, are produced. Referring to Figures 6, 7 and 8, parts of the processes depicted therein which are the same or similar to those of Figure 1, are indicated with the same reference numerals. In Figure 6, reference numeral 70 generally indicates a process according to a second embodiment of the invention for making an adhesive dressing. In the process 70, the foam coating zone 30 is dispensed with. Instead, individual absorbent fibrous material pads 32 are applied intermittently in a pad application zone 72 located after the curing/drying zone 40. In Figure 7, reference numeral 80 generally indicates a process according to a third embodiment of the invention for making an adhesive dressing. In the process 80, a hot melt adhesive is applied, in the zone 20, to the backing strip 16 at elevated temperature. The zones 30, 40 are then dispensed with. Instead, the adhesive coated strip passes through a cooling zone or stage 82 where the adhesive is cooled, whereafter individual absorbent fibrous material pads are applied thereto in the zone 72. In Figure 8, reference numeral 90 generally indicates a process according to a fourth embodiment of the invention for making an adhesive dressing. In the process 90, a hot melt adhesive is also used, with the drying/curing stage 40 of Figure 1 being replaced by the cooling stage 82. However, instead of having the pad application zone 72 of the process 80 of Figure 6, the foam coating zone 30 of Figure 1, located after the cooling stage 82 and ahead of the release paper application zone 50, is provided. If desired, curing/drying stage (not shown), similar to the stage 40, can be provided after the zone 30 and ahead of the zone 50. The Applicant believes that with the processes 10, 70, 80 and 90, adhesive dressings can be made rapidly and effectively.

Claims: A process for making an adhesive dressing, comprising passing a backing strip (16) continuously through an adhesive application zone (20); applying an adhesive to one side of the backing strip (16) as it passes continuously through this zone (20), to form an adhesive coated strip; characterized in that it comprises passing the adhesive coated strip from the adhesive application zone (20) continuously through an adhesive conditioning zone (40), to condition the adhesive; before or after the adhesive conditioning zone (40), passing the adhesive coated strip continuously through a pad application zone (30) where at least one pad (32) is applied to the adhesive coated side of the backing strip in such fashion that portions of the adhesive are not covered by the pad, thereby to form a padded strip; and feeding the padded strip continuously and directly to a release paper application zone (50), where release paper (52, 54) is applied over at least the adhesive, to form a continuous adhesive dressing. A process according to Claim 1, characterized in that the adhesive is a pressure sensitive curable adhesive, with curing of the adhesive then taking place in the adhesive conditioning zone (40). A process according to Claim 2, characterized in that the pad (32) is of curable foam material, with the adhesive coated strip passing through the pad application zone (30) before passing through the conditioning zone (40), so that curing of the foam material is also effected in the conditioning zone (40). A process according to Claim 3, characterized in that the foam material is applied continuously to the backing strip (16). A process according to Claim 3, characterized in that the foam material is applied intermittently to the backing strip (16). A process according to Claim 2, characterized in that the pad (32) is of absorbent fabric and is applied as a continuous strip to the adhesive coated strip (16). A process according to Claim 2, characterized in that individual absorbent fabric pads (32) are applied intermittently to the adhesive coated strip (16). A process according to Claim 6 or Claim 7, characterized in that the adhesive coated strip passes through the curing zone (40) before application of the pad(s) (32) thereto. A process according to Claim 1, characterized in that the adhesive is a hot-melt adhesive applied to the backing strip (16) at elevated temperature, with cooling of the adhesive being effected in the conditioning zone (40) and with the application of the pad (32) to the adhesive coated strip being after the adhesive has been cooled. A process according to Claim 9, characterized in that the pad (32) is of curable foam material, with the process including passing the padded strip through a curing stage (40) prior to entering the release paper application zone (50). A process according to any one of Claims 1 to 10 inclusive, characterized in that it includes passing the continuous adhesive dressing from the release paper application zone (50) to a cutting zone (60), and cutting it into individual dressings of a desired shape and size in the cutting zone. A process according to Claim 11, characterized in that the cutting is effected by means of a die cutting arrangement (62).

Inventors: CHARLTON DOUGLAS JOHN, SPERINCK PETER GEORGE, CHARLTON, DOUGLAS JOHN, SPERINCK, PETER GEORGE
Applicants: JOHNSON & JOHNSON CONSUMER, JOHNSON & JOHNSON CONSUMER PRODUCTS, INC.
Application year: 1994
Main classification: A61F13
IPC codes: A61F13